US9530568B2 - Method of manufacturing conductive polymer microparticle dispersion and method of manufacturing electrolytic capacitor containing the conductive polymer microparticle dispersion - Google Patents
Method of manufacturing conductive polymer microparticle dispersion and method of manufacturing electrolytic capacitor containing the conductive polymer microparticle dispersion Download PDFInfo
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- US9530568B2 US9530568B2 US14/122,247 US201314122247A US9530568B2 US 9530568 B2 US9530568 B2 US 9530568B2 US 201314122247 A US201314122247 A US 201314122247A US 9530568 B2 US9530568 B2 US 9530568B2
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- 239000006185 dispersion Substances 0.000 title claims abstract description 55
- 229920001940 conductive polymer Polymers 0.000 title claims abstract description 42
- 239000011859 microparticle Substances 0.000 title claims abstract description 38
- 239000003990 capacitor Substances 0.000 title claims description 41
- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 229920000447 polyanionic polymer Polymers 0.000 claims abstract description 51
- 238000000034 method Methods 0.000 claims abstract description 36
- 239000000178 monomer Substances 0.000 claims abstract description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000007864 aqueous solution Substances 0.000 claims abstract description 25
- 239000007800 oxidant agent Substances 0.000 claims abstract description 21
- 229920000172 poly(styrenesulfonic acid) Polymers 0.000 claims abstract description 19
- 239000002904 solvent Substances 0.000 claims abstract description 12
- 239000002019 doping agent Substances 0.000 claims abstract description 9
- 229930192474 thiophene Natural products 0.000 claims abstract description 6
- 150000003577 thiophenes Chemical class 0.000 claims abstract description 5
- 229920001467 poly(styrenesulfonates) Polymers 0.000 claims description 25
- 239000007788 liquid Substances 0.000 claims description 14
- 239000011970 polystyrene sulfonate Substances 0.000 claims description 12
- 239000007784 solid electrolyte Substances 0.000 claims description 12
- 229920000123 polythiophene Polymers 0.000 claims description 5
- 230000005180 public health Effects 0.000 claims description 2
- 229940005642 polystyrene sulfonic acid Drugs 0.000 abstract description 13
- 150000003839 salts Chemical class 0.000 abstract description 8
- 241001550224 Apha Species 0.000 abstract 1
- 230000000052 comparative effect Effects 0.000 description 21
- 238000000804 electron spin resonance spectroscopy Methods 0.000 description 14
- 229960002796 polystyrene sulfonate Drugs 0.000 description 7
- 239000000243 solution Substances 0.000 description 7
- 239000012086 standard solution Substances 0.000 description 7
- GKWLILHTTGWKLQ-UHFFFAOYSA-N 2,3-dihydrothieno[3,4-b][1,4]dioxine Chemical compound O1CCOC2=CSC=C21 GKWLILHTTGWKLQ-UHFFFAOYSA-N 0.000 description 6
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 6
- 229920000642 polymer Polymers 0.000 description 6
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 5
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 5
- 229910052744 lithium Inorganic materials 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 239000012153 distilled water Substances 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- -1 iron ions Chemical class 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000007789 sealing Methods 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 229910001870 ammonium persulfate Inorganic materials 0.000 description 3
- 229910000358 iron sulfate Inorganic materials 0.000 description 3
- BAUYGSIQEAFULO-UHFFFAOYSA-L iron(2+) sulfate (anhydrous) Chemical class [Fe+2].[O-]S([O-])(=O)=O BAUYGSIQEAFULO-UHFFFAOYSA-L 0.000 description 3
- RUTXIHLAWFEWGM-UHFFFAOYSA-H iron(3+) sulfate Chemical compound [Fe+3].[Fe+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O RUTXIHLAWFEWGM-UHFFFAOYSA-H 0.000 description 3
- 229910000360 iron(III) sulfate Inorganic materials 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 229940006186 sodium polystyrene sulfonate Drugs 0.000 description 3
- 239000011550 stock solution Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- FCEHBMOGCRZNNI-UHFFFAOYSA-N 1-benzothiophene Chemical compound C1=CC=C2SC=CC2=C1 FCEHBMOGCRZNNI-UHFFFAOYSA-N 0.000 description 2
- QENGPZGAWFQWCZ-UHFFFAOYSA-N 3-Methylthiophene Chemical compound CC=1C=CSC=1 QENGPZGAWFQWCZ-UHFFFAOYSA-N 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- YTPLMLYBLZKORZ-UHFFFAOYSA-N Thiophene Chemical compound C=1C=CSC=1 YTPLMLYBLZKORZ-UHFFFAOYSA-N 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
- 239000012895 dilution Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 159000000014 iron salts Chemical class 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- NZSSXTMHSXMZBL-UHFFFAOYSA-N 3-butoxythiophene Chemical compound CCCCOC=1C=CSC=1 NZSSXTMHSXMZBL-UHFFFAOYSA-N 0.000 description 1
- KPOCSQCZXMATFR-UHFFFAOYSA-N 3-butylthiophene Chemical compound CCCCC=1C=CSC=1 KPOCSQCZXMATFR-UHFFFAOYSA-N 0.000 description 1
- JAYBIBLZTQMCAY-UHFFFAOYSA-N 3-decylthiophene Chemical compound CCCCCCCCCCC=1C=CSC=1 JAYBIBLZTQMCAY-UHFFFAOYSA-N 0.000 description 1
- RDEGOEYUQCUBPE-UHFFFAOYSA-N 3-ethoxythiophene Chemical compound CCOC=1C=CSC=1 RDEGOEYUQCUBPE-UHFFFAOYSA-N 0.000 description 1
- SLDBAXYJAIRQMX-UHFFFAOYSA-N 3-ethylthiophene Chemical compound CCC=1C=CSC=1 SLDBAXYJAIRQMX-UHFFFAOYSA-N 0.000 description 1
- IUUMHORDQCAXQU-UHFFFAOYSA-N 3-heptylthiophene Chemical compound CCCCCCCC=1C=CSC=1 IUUMHORDQCAXQU-UHFFFAOYSA-N 0.000 description 1
- JEDHEMYZURJGRQ-UHFFFAOYSA-N 3-hexylthiophene Chemical compound CCCCCCC=1C=CSC=1 JEDHEMYZURJGRQ-UHFFFAOYSA-N 0.000 description 1
- HGDGACBSGVRCSM-UHFFFAOYSA-N 3-methoxy-4-methylthiophene Chemical compound COC1=CSC=C1C HGDGACBSGVRCSM-UHFFFAOYSA-N 0.000 description 1
- RFSKGCVUDQRZSD-UHFFFAOYSA-N 3-methoxythiophene Chemical compound COC=1C=CSC=1 RFSKGCVUDQRZSD-UHFFFAOYSA-N 0.000 description 1
- UUHSVAMCIZLNDQ-UHFFFAOYSA-N 3-nonylthiophene Chemical compound CCCCCCCCCC=1C=CSC=1 UUHSVAMCIZLNDQ-UHFFFAOYSA-N 0.000 description 1
- WQYWXQCOYRZFAV-UHFFFAOYSA-N 3-octylthiophene Chemical compound CCCCCCCCC=1C=CSC=1 WQYWXQCOYRZFAV-UHFFFAOYSA-N 0.000 description 1
- QZNFRMXKQCIPQY-UHFFFAOYSA-N 3-propylthiophene Chemical compound CCCC=1C=CSC=1 QZNFRMXKQCIPQY-UHFFFAOYSA-N 0.000 description 1
- 239000004342 Benzoyl peroxide Substances 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- FREONMIBRAAMGB-UHFFFAOYSA-L COC1=C(C=CC=C1)S(=O)(=O)[O-].[Fe+2].COC1=C(C=CC=C1)S(=O)(=O)[O-] Chemical compound COC1=C(C=CC=C1)S(=O)(=O)[O-].[Fe+2].COC1=C(C=CC=C1)S(=O)(=O)[O-] FREONMIBRAAMGB-UHFFFAOYSA-L 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- 229910001423 beryllium ion Inorganic materials 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000008151 electrolyte solution Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- JEGUKCSWCFPDGT-UHFFFAOYSA-N h2o hydrate Chemical compound O.O JEGUKCSWCFPDGT-UHFFFAOYSA-N 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- FBAFATDZDUQKNH-UHFFFAOYSA-M iron chloride Chemical compound [Cl-].[Fe] FBAFATDZDUQKNH-UHFFFAOYSA-M 0.000 description 1
- MVFCKEFYUDZOCX-UHFFFAOYSA-N iron(2+);dinitrate Chemical compound [Fe+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O MVFCKEFYUDZOCX-UHFFFAOYSA-N 0.000 description 1
- AWRGYUYRFKKAID-UHFFFAOYSA-L iron(2+);phenylmethanesulfonate Chemical compound [Fe+2].[O-]S(=O)(=O)CC1=CC=CC=C1.[O-]S(=O)(=O)CC1=CC=CC=C1 AWRGYUYRFKKAID-UHFFFAOYSA-L 0.000 description 1
- 230000002101 lytic effect Effects 0.000 description 1
- 150000007522 mineralic acids Chemical class 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- JRKICGRDRMAZLK-UHFFFAOYSA-L peroxydisulfate Chemical compound [O-]S(=O)(=O)OOS([O-])(=O)=O JRKICGRDRMAZLK-UHFFFAOYSA-L 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 239000011369 resultant mixture Substances 0.000 description 1
- 239000012085 test solution Substances 0.000 description 1
- CRUIOQJBPNKOJG-UHFFFAOYSA-N thieno[3,2-e][1]benzothiole Chemical compound C1=C2SC=CC2=C2C=CSC2=C1 CRUIOQJBPNKOJG-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/0029—Processes of manufacture
- H01G9/0036—Formation of the solid electrolyte layer
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G61/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
- C08G61/12—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule
- C08G61/122—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule derived from five- or six-membered heterocyclic compounds, other than imides
- C08G61/123—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule derived from five- or six-membered heterocyclic compounds, other than imides derived from five-membered heterocyclic compounds
- C08G61/126—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule derived from five- or six-membered heterocyclic compounds, other than imides derived from five-membered heterocyclic compounds with a five-membered ring containing one sulfur atom in the ring
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
- C08L25/18—Homopolymers or copolymers of aromatic monomers containing elements other than carbon and hydrogen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L65/00—Compositions of macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain; Compositions of derivatives of such polymers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/004—Details
- H01G9/022—Electrolytes; Absorbents
- H01G9/025—Solid electrolytes
- H01G9/028—Organic semiconducting electrolytes, e.g. TCNQ
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/15—Solid electrolytic capacitors
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2261/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
- C08G2261/10—Definition of the polymer structure
- C08G2261/14—Side-groups
- C08G2261/142—Side-chains containing oxygen
- C08G2261/1424—Side-chains containing oxygen containing ether groups, including alkoxy
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2261/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
- C08G2261/30—Monomer units or repeat units incorporating structural elements in the main chain
- C08G2261/32—Monomer units or repeat units incorporating structural elements in the main chain incorporating heteroaromatic structural elements in the main chain
- C08G2261/322—Monomer units or repeat units incorporating structural elements in the main chain incorporating heteroaromatic structural elements in the main chain non-condensed
- C08G2261/3223—Monomer units or repeat units incorporating structural elements in the main chain incorporating heteroaromatic structural elements in the main chain non-condensed containing one or more sulfur atoms as the only heteroatom, e.g. thiophene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2261/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
- C08G2261/70—Post-treatment
- C08G2261/79—Post-treatment doping
- C08G2261/794—Post-treatment doping with polymeric dopants
-
- H01G2009/0014—
Definitions
- the technical field relates to a method of manufacturing a conductive polymer microparticle dispersion applicable to an antistatic agent, a solid electrolyte for an electrolytic capacitor, a display element, etc., and the technical field also relates to a method of manufacturing an electrolytic capacitor using the conductive polymer microparticle dispersion.
- Dopant-containing polymers having a ⁇ -conjugated structure are known to have high conductivity. Dopants are substances to develop conductivity. These polymers are used in antistatic agents, display elements, etc. because of their chemical and physical stability in addition to their high conductivity. They have also been suggested to be used in solid electrolytes for electrolytic capacitors.
- One known process of manufacturing such a conductive polymer having a ⁇ -conjugated structure is to oxidatively polymerize a monomer with an oxidizing agent in the presence of a dopant.
- a dopant for example, the use of 3,4-ethylenedioxythiophene as a monomer, and a polystyrene sulfonic acid as a dopant results in highly conductive poly3,4-ethylenedioxythiophene doped with the polystyrene sulfonic acid.
- the poly3,4-ethylenedioxythiophene prepared by this method is in the form of microparticles dispersed in water.
- the above-described method can prepare a conductive polymer microparticle dispersion (see, for example, Patent Literature 1).
- Patent Literature 1 Japanese Unexamined Patent Publication No. 2008-222850
- the method of manufacturing a conductive polymer microparticle dispersion according to the present invention includes the following steps:
- the polyanion is a polystyrene sulfonic acid and/or its salt each having a Hazen color number in the range of 10 to 1000, inclusive.
- the Hazen color number is determined by measuring the hue of a 2% aqueous solution of the polyanion by the American Public Health Association (APHA) method.
- APHA American Public Health Association
- the conductive polymer microparticle dispersion prepared by the above-described method can be used as a material of a solid electrolyte for an electrolytic capacitor to drastically reduce the ESR of the electrolytic capacitor.
- FIG. 1 is a partially cutaway schematic perspective view of an electrolytic capacitor manufactured by using a conductive polymer microparticle dispersion prepared by the method according to an exemplary embodiment of the present invention.
- FIG. 2 is a partial sectional view of a capacitor element contained in the electrolytic capacitor shown in FIG. 1 .
- the electrolytic capacitor may have a high ESR depending on the method and conditions of forming a conductive polymer film. Therefore, when a conductive polymer microparticle dispersion having a ⁇ -conjugated structure is used as a solid electrolyte for an electrolytic capacitor, it is crucial to optimize the method and conditions of forming the conductive polymer film.
- FIG. 1 is a partially cutaway perspective view of an electrolytic capacitor manufactured by using a conductive polymer microparticle dispersion prepared by the method according to the exemplary embodiment of the present invention.
- FIG. 2 is a partial sectional view of a capacitor element contained in the electrolytic capacitor shown in FIG. 1 .
- the electrolytic capacitor includes capacitor element 10 , metal case 14 , and sealing member 13 .
- Case 14 houses capacitor element 10 , and sealing member 13 seals the opening of case 14 .
- case 14 and sealing member 13 together form an outer body which seals capacitor element 10 .
- capacitor element 10 includes positive electrode 1 , negative electrode 2 , separator 4 , and solid electrolyte layer 5 . Separator 4 and solid electrolyte layer 5 are interposed between positive electrode 1 and negative electrode 2 .
- Positive electrode 1 is made of an aluminum foil whose surface is etched to roughen it first and then subjected to a chemical conversion treatment to form dielectric oxide film layer 3 .
- Negative electrode 2 is also made of an aluminum foil whose surface is etched to roughen it.
- Positive electrode 1 and negative electrode 2 are connected to lead terminals 11 and 12 , respectively, as shown in FIG. 1 . Lead terminals 11 and 12 are led out through sealing member 13 .
- Capacitor element 10 includes positive electrode 1 and negative electrode 2 wound with separator 4 interposed therebetween. Capacitor element 10 is impregnated with an after-mentioned conductive polymer microparticle dispersion, and then dried to remove the solvent component. As a result, conductive polymer solid electrolyte layer 5 is formed between positive electrode 1 and negative electrode 2 .
- a dispersion liquid is prepared by dispersing, in a solvent mainly composed of water, at least one monomer selected from thiophenes and their derivatives, and a polyanion as a dopant. Then, the dispersion liquid is mixed with an oxidizing agent so as to oxidatively polymerize the monomer. The result is a conductive polythiophene microparticle dispersion doped with the polyanion.
- the polyanion is polystyrene sulfonic acid and/or its salt each having a Hazen color number in the range of 10 to 1000, inclusive.
- the Hazen color number is determined by measuring the hue of a 2% aqueous solution of the polyanion by the APHA method.
- a Hazen color number is determined by comparing the color of the solution under test with the color of a standard solution basically by human eyes.
- a standard stock solution having a known Hazen color number is prepared and diluted into several different standard solutions.
- a yellow standard stock solution APHA 500 (a Hazen color number of 500) is diluted into standard solutions having Hazen color numbers of 100, 50, and 10.
- a certain amount (X ml) of the solution under test solution is weighed, and diluted with pure water until its color becomes the same as the color of a standard solution (Hazen color number: A) when visually compared with each other.
- This standard solution seems to be paler than and be the closest to the target solution.
- the amount of the pure water used for the dilution is assumed to be Y ml.
- the dilution ratio (X+Y)/X of the solution under test is multiplied by Hazen color number A of the standard solution so as to obtain A ⁇ (X+Y)/X.
- the Hazen color number of the target solution can be determined.
- the thiophenes and their derivatives applicable as the monomer have a ⁇ -conjugated structure.
- this monomer include the following: thiophene, 3-methylthiophene, 3-ethylthiophene, 3-propylthiophene, 3-butylthiophene, 3-hexylthiophene, 3-heptylthiophene, 3-octylthiophene, 3-nonylthiophene, 3-decylthiophene, 3-methoxythiophene, 3-ethoxythiophene, 3-butoxythiophene, 3-methyl-4-methoxythiophene, 3,4-ethylenedioxythiophene, benzothiophene, and benzodithiophene.
- 3,4-ethylenedioxythiophene is especially preferable because it can be polymerized at a moderate rate and can also provide the resultant polymer with high heat resistance.
- the polyanion that can be used as the dopant includes polystyrene sulfonic acid or its salts, which may be used alone or in combination of two or more. These polyanions are excellent in dispersibility and heat resistance.
- the weight-average molecular weight of the polyanion is preferably 10000 to 400000, inclusive, more preferably 30000 to 200000, inclusive, and most preferably 50000 to 100000, inclusive.
- the number-average molecular weight of the polyanion is preferably 1000 to 300000, inclusive, more preferably 10000 to 150000, inclusive, and most preferably 20000 to 100000, inclusive.
- a first oxidizing agent may be used, which produces iron ions in a solvent.
- the first oxidizing agent include iron salts of inorganic acid such as iron chloride (III), iron sulfate (III), and iron nitrate (III); and iron salts of organic acid such as iron methoxybenzenesulfonate and iron toluenesulfonate.
- iron sulfate (III) is particularly preferable because the monomer can be polymerized at a moderate rate when using it and it can also provide the resultant polymer with high heat resistance.
- Iron sulfate (III) is hereinafter referred to as ferric sulfate.
- the first oxidizing agent is used together with a second oxidizing agent not producing iron ions in a solvent.
- the second oxidizing agent include hydrogen peroxide, persulfate, permanganate, benzoyl peroxide, and ozone.
- ammonium persulfate is especially preferable because of its following features: the monomer can be polymerized at a moderate rate when using it, it can be kept for a long period, be easy to care for, and provide the resultant polymer with high heat resistance.
- the oxidizing agent is not limited to the first and second oxidizing agents mentioned above.
- the water to be used as the solvent be ion exchange water or distilled water because of their low impurity content.
- the solvent is mainly composed of water. This means that the solvent consists of about 95% or more of water and only trace amounts of impurities or additives.
- the monomer and the polyanion are added at the same time to the water in a container under shear stress applied by a dispersing machine.
- the monomer and the polyanion may be added sequentially to the water in the container under shear stress applied by a dispersing machine.
- the monomer and the polyanion may be added to the water in the container first, and then be exposed to shear stress applied by a dispersing machine.
- the dispersing machine include a homomixer and a high-pressure homogenizer.
- Adding the monomer and the polyanion at the same time to the water takes less time for dispersion than adding them sequentially. Instead of adding the polyanion first and then the monomer, the monomer can be added first and then the polyanion. Furthermore, some of the water may be placed in the container before adding the monomer and the polyanion, and then the remaining water may be added in a plurality of batches during dispersion.
- the objective of these operations is to disperse the monomer having a hydrophobic ⁇ -conjugated structure into water by making it in the form of microparticles, and these operations are not the only possible approaches.
- a solid or viscous polyanion it can be dissolved or diluted in water and be used as an aqueous polyanion solution.
- the preferable water content is 9 parts by weight or more with respect to 1 part by weight of the monomer.
- the dispersion liquid may become too viscous during the polymerization, possibly making it impossible to obtain a uniform dispersion.
- the preferable polyanion content is 1 to 5 parts by weight, inclusive, with respect to 1 part by weight of the monomer.
- the polyanion content is less than 1 part by weight, the resultant conductive polymer has a low conductivity.
- the polyanion content is more than 5 parts by weight, the conductivity of the resultant conductive polymer hardly increases. As a result, considering the material cost, it is preferable to use 5 parts by weight or less of the polyanion.
- the monomer is oxidatively polymerized in the following manner.
- An oxidizing agent is added to the above-prepared dispersion liquid under shear stress applied by a dispersing machine.
- a solid or viscous oxidizing agent it can be dissolved or diluted in water and be used as an aqueous solution.
- the monomer in a dispersed state is oxidatively polymerized to form a polymer (hereinafter, polythiophene) in the form of microparticles.
- the monomer is kept under shear stress applied by the dispersing machine even after the oxidizing agent is added until the polymerization is over. As a result, a polythiophene dispersion doped with the polyanion is completed.
- the dispersion liquid and the oxidizing agent may be put into separate devices.
- how to oxidatively polymerize the monomer is not particularly limited as long as the dispersion liquid and the oxidizing agent are mixed with each other.
- the polyanion is a polystyrene sulfonic acid and/or its salt each having a Hazen color number in the range of 10 to 1000, inclusive.
- the Hazen color number is determined by measuring the hue of a 2% aqueous solution of the polyanion by the APHA method.
- the degree of density of the three-dimensional molecular structure of a polystyrene sulfonic acid or its salt appears as the degree of lightness or darkness of the color of the aqueous solution thereof.
- the conductive polymer having a ⁇ -conjugated structure and doped with the polyanion has a higher conductivity.
- the conductivity tends to decrease. Consequently, in order to reduce the ESR of the electrolytic capacitor, the Hazen color number is limited to the range of 10 to 1000, inclusive, by measuring the hue of a 2% aqueous solution of the polyanion by the APHA method.
- 3,4-ethylenedioxythiophene is added to distilled water in a container.
- a 29.5% aqueous solution of a polystyrene sulfonic acid is added thereto.
- the resultant mixture is exposed to shear stress applied by a homomixer for ten minutes.
- a dispersion liquid of 3,4-ethylenedioxythiophene is completed.
- the polyanion used here is a polystyrene sulfonic acid having a Hazen color number of 10 when a 2% aqueous solution thereof is measured by the APHA method.
- the dispersion liquid is under shear stress applied by the homomixer, a 2.25% aqueous solution of a ferric sulfate is added as the first oxidizing agent, and then a 28.8% aqueous solution of an ammonium persulfate is added as the second oxidizing agent. After the addition of these oxidizing agents, shear stress is applied for 24 hours by the homomixer, and then the polymerization is terminated. As a result, the conductive polymer microparticle dispersion is completed.
- Example 1 the following materials are used: 14.2 parts by weight of 3,4-ethylenedioxythiophene, 30.5 parts by weight of the polystyrene sulfonic acid, 13.0 parts by weight of ferric sulfate, 29.8 parts by weight of ammonium persulfate, and 1337 parts by weight of distilled water.
- Examples 2, 3, 4, and 5 conductive polymer microparticle dispersions are prepared in the same manner as in Example 1 except for using polystyrene sulfonic acids having Hazen color numbers of 55, 110, 489, and 1000, respectively, when 2% aqueous solutions thereof are measured by the APHA method as in Example 1.
- conductive polymer microparticle dispersions are prepared in the same manner as in Example 1 except for using, as the polyanion, ammonium polystyrene sulfonates having Hazen color numbers of 10, 318, 800, and 1000, respectively, when 2% aqueous solutions thereof are measured by the APHA method as in Example 1.
- conductive polymer microparticle dispersions are prepared in the same manner as in Example 1 except for using, as the polyanion, sodium polystyrene sulfonates having Hazen color numbers of 10, 700, and 1000, respectively, when 2% aqueous solutions thereof are measured by the APHA method as in Example 1.
- a conductive polymer microparticle dispersion is prepared in the same manner as in Example 1 except for using, as the polyanion, a lithium polystyrene sulfonate having a Hazen color number of 700 when a 2% aqueous solution thereof is measured by the APHA method as in Example 1.
- conductive polymer microparticle dispersions are prepared in the same manner as in Example 1 except for using polystyrene sulfonic acids having Hazen color numbers of 8 and 1030, respectively, when 2% aqueous solutions thereof are measured by the APHA method as in Example 1.
- conductive polymer microparticle dispersions are prepared in the same manner as in Example 1 except for using ammonium polystyrene sulfonates having Hazen color numbers of 5 and 1240, respectively, when 2% aqueous solutions thereof are measured by the APHA method as in Example 1.
- a conductive polymer microparticle dispersion is prepared in the same manner as in Example 1 except for using, as the polyanion, a sodium polystyrene sulfonate having a Hazen color number of 1050, when a 2% aqueous solution thereof is measured by the APHA method as in Example 1.
- a conductive polymer microparticle dispersion is prepared in the same manner as in Example 1 except for using, as the polyanion, a lithium polystyrene sulfonate having a Hazen color number of 8 when a 2% aqueous solution thereof is measured by the APHA method as in Example 1.
- the conductive polymer microparticle dispersions prepared by the above-described procedures contain poly3,4-ethylenedioxythiophene doped with the polystyrene sulfonic acids, or the polystyrene sulfonate, respectively. These conductive polymer microparticle dispersions are washed and filtered with distilled water, and then the concentration of the poly3,4-ethylenedioxythiophene is adjusted to 2.5%. Next, each capacitor element 10 is impregnated with the corresponding dispersion to form solid electrolyte layer 5 , thereby preparing a wound electrolytic capacitor having a rated voltage of 35 V and a capacitance of 47 ⁇ F.
- Table 1 shows the ESR values of the electrolytic capacitors manufactured with the conductive polymer microparticle dispersions of the Examples and the Comparative Examples.
- Examples 1 to 5 use, as the polyanion, the polystyrene sulfonic acids having Hazen color numbers in the range of 10 to 1000, inclusive, when 2% aqueous solutions thereof are measured by the APHA method. As shown in Table 1, in Examples 1 to 5, the electrolytic capacitors have ESRs in the range of 28.5 to 32.0 m ⁇ .
- Comparative Examples 1 and 2 use the polystyrene sulfonic acids having Hazen color numbers of 8 and 1030, respectively. As shown in Table 1, in Comparative Examples 1 and 2, the electrolytic capacitors have ESRs of 45.8 m ⁇ and 40.0 m ⁇ , respectively, which are much higher than those in Examples 1 to 5.
- Examples 6 to 9 use, as the polyanion, the ammonium polystyrene sulfonates having Hazen color numbers in the range of 10 to 1000, inclusive, when 2% aqueous solutions thereof are measured by the APHA method. As shown in Table 1, in Examples 6 to 9, the electrolytic capacitors have ESRs in the range of 28.8 to 32.2 m ⁇ .
- Comparative Examples 3 and 4 use the ammonium polystyrene sulfonates having Hazen color numbers of 5 and 1240, respectively. As shown in Table 1, in Comparative Examples 3 and 4, the electrolytic capacitors have ESRs of 47.0 m ⁇ and 43.4 m ⁇ , respectively, which are much higher than those in Examples 6 to 9.
- Examples 10 to 12 use, as the polyanion, the sodium polystyrene sulfonates having Hazen color numbers in the range of 10 to 1000, inclusive, when 2% aqueous solutions thereof are measured by the APHA method. As shown in Table 1, in Examples 10 to 12, the electrolytic capacitors have ESRs in the range of 29.5 to 32.3 m ⁇ .
- Comparative Example 5 uses the sodium polystyrene sulfonate having a Hazen color number of 1050. As shown in Table 1, in Comparative Example 5, the electrolytic capacitor has an ESR of 40.6 m ⁇ , which is much higher than those in Examples 10 to 12.
- Example 13 uses, as the polyanion, the lithium polystyrene sulfonate having a Hazen color number of 700 when a 2% aqueous solution thereof is measured by the APHA method. As shown in Table 1, in Example 13, the electrolytic capacitor has an ESR of 29.7 m ⁇ .
- Comparative Example 6 uses the lithium polystyrene sulfonate having a Hazen color number of 8. As shown in Table 1, in Comparative Example 6, the electrolytic capacitor has an ESR of 47.7 m ⁇ , which is much higher than that in Example 13.
- the ESR of the electrolytic capacitor can be reduced by using, as polyanion, a polystyrene sulfonic acid or its salt each having a Hazen color number in the range of 10 to 1000, inclusive, when a 2% aqueous solution thereof is measured by the APHA method. It has also been found that in the case of using the salt as the polyanion, cation is not particularly limited.
- the present exemplary embodiment has described a wound solid electrolytic capacitor containing an aluminum foil as an electrode, but the present invention is not limited to this configuration.
- the conductive polymer microparticle dispersions manufactured according the method of the present exemplary embodiment can be applied, for example, to the following capacitors: a wound solid type including an electrode made of valve metal foil other than aluminum; a stacked type; a type including a positive electrode made of a sintered valve metal; and a hybrid type containing both a solid electrolyte and an electrolytic solution.
- the present invention is useful for an electrolytic capacitor employing a conductive polymer microparticle dispersion.
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Abstract
Description
TABLE 1 | ||||
the hue of an aqueous | ESR of electro- | |||
solution of polyanion | lytic capacitor | |||
polyanion | (Hazen color number) | (mΩ) | ||
Example 1 | |
10 | 32.0 | |
Example 2 | PSS | 55 | 28.5 | |
Example 3 | PSS | 110 | 29.5 | |
Example 4 | PSS | 489 | 30.5 | |
Example 5 | PSS | 1000 | 32.0 | |
Example 6 | |
10 | 32.2 | |
Example 7 | APSS | 318 | 28.8 | |
Example 8 | APSS | 800 | 29.0 | |
Example 9 | APSS | 1000 | 28.8 | |
Example 10 | |
10 | 32.3 | |
Example 11 | SPSS | 700 | 29.5 | |
Example 12 | SPSS | 1000 | 30.0 | |
Example 13 | LPSS | 700 | 29.7 | |
Comparative | PSS | 8 | 45.8 | |
Example 1 | ||||
Comparative | PSS | 1030 | 40.0 | |
Example 2 | ||||
| APSS | 5 | 47.0 | |
Example 3 | ||||
Comparative | APSS | 1240 | 43.4 | |
Example 4 | ||||
Comparative | SPSS | 1050 | 40.6 | |
Example 5 | ||||
Comparative | LPSS | 8 | 47.7 | |
Example 6 | ||||
PSS: polystyrene sulfonic acid | ||||
APSS: ammonium polystyrene sulfonate | ||||
SPSS: sodium polystyrene sulfonate | ||||
LPSS: lithium polystyrene sulfonate |
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